Apparatus for producing soap



Nov. 5, 1935. B, CLAYTON ET AL APPARATUS FOR PRODUCING SOAP OriginalFiled June 28, 19515 2 Sheets-Sheet l MOD/F/ER FAT REAGENT WA TER ATToR/VE-Y.

Nov. 5, 1935.

B. CLAYTON ET AL APPARATUS FOR PRODUCING SOAP Original Filed June 28,1933 2 Sheets-Sheet 2 [/v VE/v Toms E/VL/AM//v CLA yTo/v RALPH VE/i577@UR/v6 A TToR/vfy,

Patented Nov. 5, 1935 i UNITED STATES PATENT OFFICE APPARATUS FORPRODUCING SOAP Nevada Original application June 28, 1933, Serial No.678,030. Divided and this application July 13, 1934, Serial No. 734,962

' 5 Claims.

Our invention relates to the manufacture of soap and the principalobject of the invention is to provide a process and apparatus forproducing soap in a very rapid, economical, and elllcient manner.

A further object of the invention is to provide a continuous process bywhich a saponiable fat is converted into bar soap by a continuousprocess.

Further objects and advantages of our invention will be made evidenthereinafter.

In the process of producing soap it is standard practice to mix asaponifying alkali, hereinafter sometimes called the reagen with asaponithe fat, and to agitate and heat the mixture until the fat isbroken up into glycerine and fatty acids, the fatty acids combining withthe alkali to produce the soap. By the term saponifiable fatwe wish tobe understood to mean any fat which could be used in the known processesof making soap, and by a saponifying alkali we wish to be understood tomean any of the alkalies which are at present used in soap making. Inpractice we prefer to use an aqueous solution of caustic soda, althoughcaustic potash, 'soda ash, and other alkalies may be used.

'Ihe process of making soap which is generally practiced involves theplacing of the fat in a large kettle in which it is heated and to whichthe alkali is added, the fat being' agitated during this addition toproduce an intimate mixture of the alkali with the fat. After the fatand alkali have been thoroughly mixed together 35 in the properproportions, which is readilyl determined by the skilled soap maker, thecharge is heated and agitated for av considerable period untilpractically all of the fats are broken up and the fatty acids thereofare combined`with the alkali.

Our process has many advantages over the present s'oap making processes,as willbe made evident hereinafter.

A convenient apparatus for .carrying on the process invented by us isshown in the accompanying drawings, in which,

Fig. 1 is a diagrammatic representation of an assembly of differentunits usKed to carry Von the process.

Fig. 2 is a.` cross-section through a convenient form of mixer.

Fig. 3 is a section through. the ejector nozzle cf the invention Ashownin Fig.V 1.'

fiable fat, hereinafter sometimes called simply Fig. 4 is aplan viewpartially in section of the lower portion of the heater 6 showing thethermostat and burner.

Fig. 5 is a section drawn on an enlarged scale through the right-handend of the thermostat as viewed in Fig. 1. 5

Fig. 6 is a section showing the method of supporting the thermostat.

Fig. 7 is a section on an enlarged scale through the left-hand end ofthe thermostat as viewed in Fig. 1.

The apparatus employed consists of a fat pump I, a reagent pump 2, aprimary water pump 3, a secondary water pump 4, a mixer 5, a heater 6, acooler 1, an extruder 8, a modifier pump 9, and a bar fabricator I0.

The pump l is driven directly from a main shaft l2 which is driven by amotor The pump I draws fat through a pipe |3 from a fat supply tank I4and delivers this fat under pressure through a pipe I5 to the mixer 5.

The reagent pump 2 ls driven from the main shaft 2 through a variablespeed gear 2|, the pump 2 taking reagent through a pipe 22 from areagent tank 23 and delivering this reagent through a pipe 24 to themixer 5.

The variable speed gear 2| and certain other variable speed gears 34,43, and 94, hereinafter referred to, are shown diagrammatically asconsisting of two reverse cone pulleys connected by a belt, the positionof which on the pulleys can be fixed in any position by the operator ofthe plant, thus fixing the relative speeds of the two pulleysl at aratio between a lower and a higher limit. This type of variable speeddrive is used merely for illustrative purposes since it is well known inthe arts. Other types of variable speed gears by which the operator canregulate the proportional speed of any pump may be substituted thereforif desired. I

The exact form of the mixer 5 is not impor- 40 tant, that shown in Fig.2, however, being a convenient form. In` the form shown a casing 5|surrounds a central pipe 52 through which the lreagent is pumped, thefat from the pipe l5 being delivered to the space around this centralpipe 52. The reagent and fat are combined or mixed as they leave themixer 5 and the mixture so produced is delivered through a pipe 53 tothe heater 6. Y

The heater 6 consists of an outer shell 6| in 50 which is mounted a pipecoil 62. The lower end of this pipe coil delivers liquid to a thermostat63 from which the liquid is delivered through a pipe 64 to the cooler 1.A valve or other control device 89 controls the liow of gas or otherfuel 55 from a pipe 66 to a burner 61, the valve 63 having the functionof regulating the supply of gas passed to the burner. The thermostat 63forms an automatic means responsive to changes in temperature of theliquid passing therethrough from the coil 62 for actuating the controldevice. Adjusting means 68 may be provided on the thermostat. The hotproducts of combustion from the burner 6T constitute a heating mediumfor the coil 62 and the amount of heat delivered to this coil is, ofcourse, regulated by the amount of gas which is passed to the burner.

. The heater shown is that disclosed in the application of Walter B.Kerrick, Serial 495,635, led Nov. 14, 1930, Figs. 4, 5, 6, and 7 beingdrawings copied from that application.

The end of the coil 62 communicates with an opening 63| whichcommunicates with an inner pipe 632, the end of which is open as shownin Fig. 5 and which communicates with an outer pipe 633. This outer pipeconnects to the pipe 64 so that liquid from the coil 62 flows throughthe pipe 632 into the right-hand end of the pipe 633 and inside thispipe from right to left, this liquid being finally delivered to the pipe64. Due to the passage of hot liquid through the pipes 632 and 633 thepipe 633 expands or contracts and operates a valve 69| forming part ofthe control device E9 as shown in Fig. 5, being operated through a stem692 from the pipe 633. The expansion or contraction of the pipe 633therefore moves the valve 69| towards or away from a seat 694 whichcontrols the flow of gas from the pipe 66, thus regulating the amount ofgas delivered to the burner 61. The adiusting means 63 shown in Fig. 7tends to move the thermostat bodily so that the temperature at which thevalve 69| closes may be regulated by the operator at will. The entirethermostat is mounted on a ring 635 which encircles the shell 6| and issupported on suitable lugs 636.

'I'he cooler 'l may be of any convenient form, that shown consisting ofa tank 1| inside which is a cooling coil l2, the inlet end of which isconnected to the pipe 64. Cooling water is delivered to the tank 1|through a pipe 3| from the primary water pump 3, this water being takenthrough a pipe 32 from a water tank 33. The primary water pump 3 isdriven from the shaft |2 through a variable speed gear 34. Excess waterand steam are removed from the top of the tank 1| through a release pipe13. The coil 12 is connected through a pipe 14 to the upper end of theextruder 3.

Modifier may be delivered to the coil 12 through a pipe 9| from themodifier pump 9, this pump drawing material through a pipe 32 from a.tank 93. The pump 9 is driven from the shaft I2 through a variable speedgear 64. The extruder 6 consists preferably oi' a-cylindrical tank 3|inside which is placed an extrusion member 62 which may have a roundbore or a rectangular bore as shown. Water is delivered to the bottom ofthe cylindrical casing 3| through a pipe 4| from the pump 4, this waterbeing drawn through a pipe 42 from the water tank 33. The pump 4 isdriven from the shaft I2 through a variable speed gear 43.

The bar fabricator I6 is well known in the art and the details thereofwill not be described. Its purpose is to receive a continuously extrudedbar of solidified soap and to cut it up into bars, or, if necessary, tocut it up into flakes or granules.

The materials in the tanks I4, 23, 33, and 33 are replenished from timeto time as they become partially used and automatic means foraccomplishing this may be provided if desired.

If the fat which is used is not liquid at room temperatures, means, notshown, must be provided in the tank i4 for heating it so that it isrendered sufficiently liquid to pump readily.

Suitable valves, not shown, are provided for controlling the flow ofliquids conveniently, and suitable gauges and thermometers, not shown,u) are provided for indicating conditions within the apparatus.

The method of operation is as follows:

Fat is pumped continuously by the pump from the tank I4 through the pipe|5 into the 15 mixer 5. The speed at which the fat is pumped may beregulated by changing the speed of the motor H.

Reagent is pumped continuously from the tank 23 to the mixer 5 throughthe pipe 24 by the 20 pump 2. The variable speed gear 2| permits therate at which reagent is added to the fat to be varied within limits.'I'he proportion of reagent so added depends, of course, upon thecharacter of the fat used. If an aqueous solution of caustic 25 soda isused having a gravity of 30 Baume and a mixture of equal parts of tallowand cocoanut oil is to be treated, it will be found that if reagent issupplied at the rate of about forty-five per cent of the volume of thefat, good results 30 will be obtained. The amount of reagent whichshould be supplied to produce good saponication without leaving too muchexcess reagent or excess unsaponiiied fat is, of course, readilydeterminable by any skilled soap maker. 35

Using a coil 62 consisting of about 300 feet of pipe 1/2 inch insidediameter, good results can be obtained if from one-third gallon to onegallon per minute of fat is delivered to the mixer 5.

The pumps and 2, the variable speed gear 2|, 40 and the mixer 5, takencollectively, constitute a proportioning device having the function ofdelivering a mixture of fat and reagent (in proper proportions) to thecoil 62 of the heater. Other means of performing this function will beobvious 45 to one skilled in the art, For example, the mixture of fatand reagent may be produced in the tank I4, in which case the tank 23,the pump 2, the variable speed gear 2|, and the mixer 5 may be dispensedwith, the pipe i5 being connected 50 to the pipe 53. The arrangementshown has, however, certain advantages, among which may be mentioned theautomatic mixing in the right proportion and the ease by which thisproportion can be changed by varying the speed of the 5 pump 2 bymanipulating the variable speed gear 2|.

The function of the mixer 5 is to bring the fat and reagent together andwhile the mixer shown `iets the reagent into the oil, and this is aconvenient method of producing an intimate mixture, this is notnecessary since the fat and reagent are thoroughly mixed due to the mildturbulence produced in the coil 62.

'I'he function of the heater 6 is primarily to 65 raise the temperatureof mixture of fat and reagent to a point at which saponiflcation isfacilitated. It.will be found that excellent results are obtained if atemperature of from 400 to 500 F. is maintained in the coil 62. Forreasons Winch will be hereinafter explained it will be found possible tomaintain a pressure of from to 500 pounds per square inch on the liquidleaving the coil 62 and this pressure also assists in splitting the fatinto free fatty acid and glycerine, the free 75 insure that the mixtureflowing through the pipe 64 is maintained at a constant temperature. Anyincrease in this temperature expands the lpipe 633 and tends to forcethe valve 69| towards its seat 694. This tends to reduce the amount offuel gas passing to the burner 61 and this reduces the volume of theheating medium; that is, the hot products of combustion, passing fromthe burner 61 up into the space surrounding the coil 62 where it isavailable to heat the mixture of fat and reagent passing through thecoil l2.

'I'he material passing through the pipe B4 is preferably in liquidcondition. This material is cooled in the cooler 1. The de'gree of thiscooling is regulated by adjusting the amount of water supplied to thecooler 1 by the pump 3. This regulation can be conveniently madeby-adjust ing the speed of the pump 3 by the variable speed gear 34. Dueto the fact that the pumps l, 2, and 3 are all driven by the shaft i2,all three pumps act as proportioning pumps, so that the amount ofcooling in the cooler 1 is proportioned to the rate of supply of rawmaterials and varies directly with any variation in that rate.

In the production of soap it is often desired to add to the soap duringmanufacture certain substances such as inert fillers, coloring, or scentproducing substances, or-the like. It is often desirable to introducesuch substances after the temperature of the soap has been loweredsomewhat from that at which the reaction is produced.. For conveniencewe call all such substances modifiers". They may affect either thephysical or chemical characteristics of the soap,

or both.

. Such modifiers may be conveniently introduced into the coil 12 of thecooler 1 through the pipe 9i from the pump 9. Since this pump is alsodriven from the shaft i2 through the variable speed gear 94, theproportion in which modifier is introduced can be maintained constant orvaried by the operator of the plant.

'I'he functions of the extruder BI are two in number. First, it formsahomogeneous bar of solid soap which iscontinuously fed out of thebottom end thereof as shown at illi; and, second, it provides suflicientfriction resistance to the flow of this-bar to allow a considerablepressure to be carried in the coil 62.

In practice it is preferable to so regulate the cooling of the soap inthe cooler 1. that it is still liquid as it passes through the pipe 14into the upper end of the extrusion member 42. 'I'he soap then graduallycools as it passes downwardly.

. lated by manipulating the variable speed gear 4l.

The regulation of the plant is somewhat improved if a member 16 having aconstricted orince is placed in the pipe 64. The hot material flowingfrom the heater 6 to the cooler 1 passes through this constrictedorifice and considerable fluid friction is built up therein. 'Ihls fluidfriction is not dependent upon the action of the extruder but is largelydependent upon the Iamount of steam formed in the coil 62. 'I'his steamis, of 5 course, condensed inthe cooler 1. If the amount of steamproduced in the coil 62 is increased so that -the volume of the materialpassing through the constricted orifice of the member 16 is increased,the pressure drop in the constricted orifice is increased and thepressure in the cooler 1 available to produce extrusion through, theextruding nember 82 is lowered. This slows down the extrusion and theamount of steam passing through the orice in the member 16 falls, thusdecreasing nthe pressure drop in the orifice and increasing the pressureavailable for extrusion.

This application is a division of our application Serial 678,030, filedJune 28, 1933.

We claim as our invention:

1. An apparatus for producing soap, comprising: a heater for raising thetemperature of a mixture of saponifiable fat and saponifying alkali byheat transmitted through the walls thereof pumping means for supplyingsaid mixture to said heater by applying sufficient pressure thereto tocause said mixture to flow into said heater against any pressure thatmay be built up therein; a cooler for reducing the temperature of thesoap produced invsaid heater so that said soap is solidified by removingheat from said soap through the walls of said cooler; and a, memberhaving an orifice through which said soap is ejected after it leavessaid cooler, said orifice being so proportioned as to insure thebuilding up of considerable pressure in said cooler by exertingfrictional resistance on said solidified soap.

2. An apparatus for producing soap, comprising: a heater for raising thetemperature of a mixture of saponiable fat andfsaponifying alkali byheat transmitted through the walls thereof; pumping means for supplyingsaid mixture tosaid heater by applying suflicient pressure thereto tocause said mixture to flow into said heater against any pressure thatmay be built up therein; means for supplying heat to the liquid in saidheater by supplying a hot heating medium to said heater; a cooler forreducing the temperature of the soap produced in said heater so that/said soap is solidified by removing heat from said soap through thewalls of said cooler; and a member having an orifice through which saidsoap is ejected after it leaves said cooler, said orice being soproportioned as to insure the building up of considerable pressure insaid cooler by exerting frictional resistance on said solidified SORP-3. An apparatus for producing soap, comprising: a heater for raising thetemperature of a` mixture of saponiable fat and saponifying alkali byheat transmitted through the walls thereof; pumping means for supplyingsaid mixture to said heater by applying suflicient pressure thereto tocause said mixture toflow into said heater V against any pressure thatmay be built up therein; I

means for supplying heat to the liquid in said heater by supplying ahotheating medium to said heater; a control device for regulating theamount of heat supplied to said heater by controlling the supply of hotheating medium thereto; a cooler for reducing the temperature'of thesoap produced in said heater so that said soap is solidified by removingheat from said soap through the walls of said cooler; and a memberhaving an orifice through which said soap is ejected after it leavessaid cooler, said oriilce being so proportioned as to insure thebuilding up of considerable pressure in said cooler by exertingi'rictional resistance on said solidified soap.

4. An apparatus for producing soap, comprising: a heater for raising thetemperature of a mixture of saponiilable fat and saponifying alkali byheat transmitted through the walls thereof; pumping means for supplyingsaid mixture to said heater by applying sumcient pressure thereto tocause said mixture to ilow into said heater against any pressure thatmay be built up therein; means for supplying heat to the liquid in saidheater by supplying a hot heating medium to said heater; a controldevice for regulating the amount of heat supplied to said heater bycontrolling the supply of hot heating medium thereto; automatic meansresponsive to changes in the temperature of the soap leaving said heaterfor insuring a constant temperature on said soap by operating saidcontrol device; a cooler for reducing the temperature of the soapproduced in said heater so that said soap is solidified by removing heatfrom said soap through the walls of said cooler; and a member having anorince material and the reagent is produced; means for 10 supplying heatto the mixture of saponiilable material and reagent While said materialis in said heater; pumping means for pumping said mixture continuouslyinto said heater; walls forming an orifice through which the soapproduced 15 by said reaction is extruded due to the pressure produced bysaid pumping means; and means for regulating the pressure maintained inthe heater by cooling the soap after it leaves the heater and before itreaches the orifice and thus regugo lating the friction of extrusion andthe back pressure produced thereby.

BENJAMIN CLAYTON. RALPH EVERE'I'I BURNS. y

